Torque limiter devices, systems and methods and solar trackers incorporating torque limiters

ABSTRACT

A solar tracker assembly comprises a support column, a torsion beam connected to the support column, a mounting mechanism attached to the torsion beam, a drive system connected to the torsion beam, and a torsion limiter connected to an output of the drive system. When an external force causes a level of torsion on the drive system to exceed a pre-set limit the torsion limiter facilitates rotational movement of the solar tracker assembly in the direction of the torsion, thereby allowing the external force to rotate about a pivot axis extending through the torsion beam. Exemplary embodiments also include methods of aligning a plurality of rows of solar trackers.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of and claims priority to U.S. patentapplication Ser. No. 14/624,930, filed Feb. 18, 2015, which is anon-provisional of and claims priority to U.S. Patent Application Ser.No. 61/941,754, filed Feb. 19, 2014, and U.S. Patent Application Ser.No. 62/065,741, filed Oct. 19, 2014, each of which is herebyincorporated by reference in its entirety.

FIELD

The present disclosure relates to torsion limiter devices, systems, andmethods. The present disclosure further relates to torque releasemechanisms in mechanical positioning systems. The present disclosurefurther relates to torque limiting and slip clutch assemblies.

BACKGROUND

As the wind acts on a solar tracking photovoltaic (PV) array or othermechanically driven positioning systems exposed to outdoor environmentalforces, it causes positive and negative pressures on the array which mayact independently, cumulatively, or differentially. These wind forcesare commonly categorized as drag, uplift, downforce and hinge momentabout the rotational axis. The wind forces vary depending upon the windspeed, direction and rotational tracking angle of the array. Theseforces are also usually greater on the outer structures in a large arrayfield.

Typically, in the case of single axis solar tracking systems, the liftand drag induced on the tracked array or other mechanical system areresisted at multiple points within the structure. However, as evidencedby existing systems, the hinge moment typically is resisted at a singlepoint. The resulting torsional forces applied to relatively long torsiontubes or other beam configurations may be large and tend to interactwith the torsional flexibility of the tracker structure. Counteractingthe high hinge moment forces at a single point in the structure requiressufficiently strong torsional members to resist both the high combinedtorque and the beam loads of the system without excess flexibility. Thehinge moment forces may present as a static force or sometimes dynamicforce known as torsional divergence. If the structural system of thetracker is flexible in its design, and is torsionally restrained at asingle point, torsional divergence and other dynamic forces may occurthat have the potential to substantially increase the loading on thestructure. It is therefore structurally advantageous to minimize theflexibility of the tracker structure to reduce or eliminate the windinteractions that may cause these dynamic forces.

Accordingly, there is a need for a mechanism to reduce the peak hingemoment force that a tracking system will be exposed to and/or allow thesystem to resist the moment forces at multiple points, therebyminimizing or effectively eliminating the dynamic/harmonic forces thestructure is exposed to. Minimizing torsion in the structure increasesthe beam load capability of the relevant structural members since thecombination load of the torsion and beam loading is less. By limitingthe peak torsion force and then providing a means to resist a lowermaximum torsion force at multiple points along the structure, lighterstructural components may be incorporated to lower the material weightand cost of solar tracker systems.

SUMMARY

Exemplary embodiments of the present disclosure alleviate to a greatextent the disadvantages of known mechanical systems such as solartrackers by incorporating a torsion limiter, which may in some instancesbe a torque limiting clutch, at the output of a primary gearbox, priorto the engagement of a secondary gear rack in each tracker row. Inessence, this places a pre-set torque release mechanism between thetorsion stressed components and the drive in each individually motorizedor linked tracker row of a tracker system. Exemplary embodiments of thisdisclosure advantageously minimize the wind induced torsion forces onthe tracker array in order to materially reduce the structuralrequirements of the tracking system. Materially reducing structure mayresult in a considerable reduction in the cost of the tracker system.

Exemplary embodiments of a torsion limiter act as a torsional forcerelief valve that minimizes the hinge moments and eliminates anysignificant dynamic forces that may be induced by the wind on mechanicalsystems such as PV tracking structures. An important function is torelieve the torsion during high wind events and allow each individualtracker row to move to a different position until either the array movesto a position in which the torsion force is no longer able to overcomethe preset torsion release force, or the array is moved by the torsionalforce to the extreme angles of rotation and is then restrained atmultiple points on the structure. Incorporating multiple stops along thearray at the extreme rotation positions minimizes the torsion force inany one section of the torsional resisting structural component orcomponents.

In exemplary embodiments, the torsion limiter may also act as anoverload relief from the input force of the drive motor if the arraycannot move due to an obstruction such as an unbalanced heavy snow load,snow drift, or sand dune, or if one or more of the linked gear sets areat an extreme limit stop condition. In this condition the torsionlimiting clutch will de-couple the input driving forces from the outputforces if the obstruction resistance is greater than the torsionlimiting threshold. In exemplary embodiments, the forces that will bereleased by the torsion limiter will be both the hinge moment forcesinduced externally on the array, and also from the input drivingmechanism, when the input driving forces required to move the array areabove the torsion limiter threshold.

Exemplary embodiments of a solar tracker assembly comprise a supportcolumn, a torsion beam connected to the support column, a mountingmechanism attached to the torsion beam, a drive system connected to thetorsion beam, and a torsion limiter connected to the drive system. Thesolar tracker assembly may include a plurality of support columns andfurther comprise a stop at each support column. The torsion beam may beconfigured with a balanced center of gravity such that it rotates aboutthe balanced center of gravity. When an external force such as the windcauses a level of torsion in the system to exceed a pre-set limit, thetorsion limiter then facilitates rotational movement of the solartracker assembly in the direction of the torsion, thereby allowing theexternal force to rotate the assembly about a pivot axis extendingthrough the torsion beam.

In exemplary embodiments, the torsion limiter de-couples excess torsionsuch that the external force is released by allowing the array to moveto a second rotational position. The movement in the direction of thetorsion may comprise movement of the solar tracker assembly from a firstrotational position to at least one second rotational position. Inexemplary embodiments, when the external force is great enough, thesolar tracker moves to an extreme rotational position stop position. Themaximum rotational position mechanical stop is at a maximum angle ofrotation and is then resisted at multiple points in the trackingstructure so that the main torsional resisting structural member isultimately supported rotationally at multiple points, effectivelylimiting the torsion in the torsion beam structure.

The movement in the direction of the torsion may comprise movement ofthe solar tracker assembly from a first rotational position to a secondor multiple rotational positions. In exemplary embodiments, the solartracker assembly is constrained in its maximum rotational positions atmultiple distributed locations along a torsional resisting structure ofthe solar tracker assembly. The torsion limiter limits the hinge momentabout the pivot axis extending through the torsion beam when the trackeris not at the extreme positions by allowing the tracker to rotate torelease torsional force and then the multiple stops at the extremepositions ultimately limit the torsion in any one section of the torsionresisting structural member when the system cannot rotate any further.

In exemplary embodiments, the drive system of the solar tracker assemblycomprises a gear assembly including at least one gear wheel. Inexemplary embodiments, the gear assembly includes a one-way gearbox andthe torsion limiter is a torsion limiting clutch. The torsion limitermay also be a slip clutch in some embodiments. In exemplary embodiments,the gear assembly includes a friction coupling engaging the gear wheeland the torsion limiter is located at the friction coupling. The torsionlimiter may be located at the output of a first gear stage of the gearassembly. In other exemplary embodiments, the solar tracker assembly isa push/pull linked tracker and the torsion limiter is a linear slipdevice or linear clutch linkage. The solar tracker assembly may includea hydraulic system and the torsion limiter may be in the form of apressure relief valve in the hydraulic system. The solar trackerassembly may further comprise a damper incorporated at or near the gearrack to control the release of torsional force and slow the motion ofthe solar tracker assembly.

Exemplary embodiments include methods of aligning a solar arraycomprising a plurality of rows of solar trackers, providing a torsionlimiter individually connected to each row of solar trackers, where oneor more of the solar trackers encounter a mechanical rotational limitwhich causes the level of torsion induced by the driveline in the atleast one row of solar trackers to exceed the torsion limit threshold,whereby the torsion limiter allows the mechanically limited at least onerow not to rotate while simultaneously driving the rotation of the othermultiple rows of solar trackers. The plurality of rows of solar trackersincludes multiple rows of linked solar trackers. The mechanical limitcondition on at least one row of solar trackers of the multiple rows ofsolar trackers creates a level of torsion in the tracker that exceeds apre-set threshold.

The at least one mechanically limited row does not rotate while theother multiple rows of solar trackers rotate and reach their maximummechanical limit position until all of the plurality of rows of solartrackers are no longer rotating. As each row reaches its maximummechanical limit position, each tracker row stops rotational movementwhile the other multiple rows of solar trackers rotate and reach theirmaximum limit positions. When all the tracker rows reach theirmechanical limits, they are all in alignment.

The same mechanism that limits and releases the driving torque at a safethreshold is also advantageous if one or more tracker rows areobstructed from external environmental conditions such as a snow drift,sand dune or other impediment. The torsion limiter may protect thetracked array from damage by the obstruction while also allowing thetracker to rotate in a limited motion until the obstruction is cleared.

In exemplary embodiments, during over torsion from external forces, themovement in the direction of the torsion comprises movement of at leastone row of solar trackers from a first rotational position to at leastone second rotational position. The movement in the direction of thetorsion may comprise movement of at least one row of solar trackers froma first rotational position to multiple rotational positions. Inexemplary embodiments, the at least one row of solar trackers hitsmultiple mechanical constraints in the multiple rotational positions ormaximum limit positions. Each row of solar trackers may include aplurality of support columns and a stop at each support column.Exemplary embodiments further comprise incorporating a damper near or atthe torsion limiter to control the release of torsional force and slowthe motion of the solar tracker assembly.

Exemplary embodiments of a singular motorized solar tracker assemblycomprise a support column, one or more torsion beams connected to thesupport column, a solar module mounting system attached to the one ormore torsion beams, a drive system connected to the one or more torsionbeams, and a motor brake. The drive system comprises a bi-directionalgearbox having an input and an output, and the motor brake is located atthe input of the bi-directional gearbox. When an external force causes alevel of torsion on the drive system to exceed a pre-set limit, themotor brake slips, or if the motor brake is internal to the motor itselfthe motor is driven backwards through the system, which facilitatesback-driving of the system and release of the torsional force.

In exemplary embodiments a gear drive system comprises a gear assemblyincluding a torque-limiting clutch and at least one worm gear wheel. Thegear assembly may or may not be contained in a gearbox. When a level oftorque on the gear exceeds a preset level the clutch slips. The gearassembly may include two taper sections engaging the worm gear wheel. Inexemplary embodiments, the torque limiting clutch is located at the twotaper sections. The clutch may be adjustable via a nut that varies thespring tension at the taper sections. This slip clutch may takealternate forms in exemplary embodiments and in other forms as necessaryfor different types of gear-driven mechanical systems.

In exemplary embodiments, a solar tracker assembly comprises at leastone support column, a torsion beam connected to the support column, witha pivot axis extending through the torsion beam, a mounting mechanismattached to the torsion beam, one or more solar modules mounted to themounting mechanism, and a gearbox assembly containing a torque limitingclutch and at least one worm gear wheel. When a level of torque on thegearbox exceeds a preset threshold, the clutch slips.

Exemplary embodiments of a gear-driven mechanical system comprise atleast one gear-driven mechanical unit including at least one gear rackand a gear drive system engaging with the gear rack. The gear drivesystem comprises a gear assembly including at least one gear wheel, anda torque-limiting clutch located at an output of the gear assembly andprior to a location where the gear drive system engages the gear rack.When a level of torque on the gear assembly exceeds a preset level theclutch slips, releasing the torque on the gear-driven mechanical unit.

In exemplary embodiments, the gear assembly includes at least one tapersection engaging the gear wheel and the torque limiting clutch islocated at the taper section. The clutch may be adjustable via a nutthat varies the spring tension at the taper section. In exemplaryembodiments, the gear-driven mechanical unit is rotatable. In exemplaryembodiments, the gear-driven mechanical unit rotates to a hard stopposition at its maximum angle of rotation.

Exemplary embodiments of a gear-driven mechanical system comprise atleast one gear-driven mechanical unit rotatable about a rotational axisand a gear drive system. The gear-driven mechanical unit includes atleast one gear rack and the gear drive system engages with the gearrack. The gear drive system comprises a gear assembly including at leastone gear wheel and a torque limiting clutch located at an output of thegear assembly. When a level of torque on the gear assembly exceeds apre-set level, the clutch slips, releasing the torque on the gear-drivenmechanical unit and limiting a hinge moment about the rotational axis.

In exemplary embodiments, the torque limiting clutch is located at theoutput of a first gear stage of the gear-driven mechanical unit. Inexemplary embodiments, the torque limiting clutch is incorporated in theinput to the gear rack of the gear-driven mechanical unit. The at leastone gear-driven mechanical unit may comprise a plurality of gear-drivenmechanical units. In exemplary embodiments, each gear-driven mechanicalunit rotates to a mechanically limited stop position at its maximumangle of rotation.

Exemplary embodiments of a solar tracking system comprise at least onesolar tracker assembly being held rotationally through a torque-limitingclutch. The solar tracker assembly includes at least one support column,a torsion beam connected to the support column, a module mounting meansattached to the torsion beam, and at least one gear drive assemblyconnected to the torsion beam. A pivot axis extends through the torsionbeam. The torque limiting clutch engages the gear drive assembly. Whenthe level of externally applied torque on the gear drive assemblyexceeds a preset level, the clutch slips allowing the tracking system torotate, thereby releasing the torque on the solar tracker assembly andreducing the hinge moment about the pivot axis.

In exemplary embodiments, the torque limiting clutch is located at theoutput of a first gear stage of the solar tracker assembly. In exemplaryembodiments, the torque limiting clutch is incorporated in the geardrive assembly of the solar tracker assembly. The gear drive assemblymay include a main driving gear wherein the torque limiting clutch isincorporated on an output of the main driving gear. In exemplaryembodiments, the solar tracker assembly rotates to engage a mechanicalstop at its maximum angle of rotation.

The solar tracking system may be a linked system wherein the torquelimiting clutch is incorporated between an arm connection and thetorsion tube. The solar tracking system may be a push/pull linkedtracker. In other exemplary embodiments, the solar tracking system ishydraulically driven, and the torque limiting clutch is a pressurerelief valve.

Accordingly, it is seen that torsion limiters, torque-limiting clutches,gear drive systems, solar trackers, and related torque release methodsare provided. The disclosed devices, systems, and methods provide apreset torque release mechanism, thereby reducing or eliminating thehinge moments and other dynamic forces on the PV tracking structure.These and other features and advantages will be appreciated from reviewof the following detailed description, along with the accompanyingfigures in which like reference numbers refer to like parts throughout.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned features and objects of the present disclosure willbecome more apparent with reference to the following description takenin conjunction with the accompanying drawings wherein like referencenumerals denote like elements and in which:

FIG. 1A is a schematic of an exemplary embodiment of a mechanical unitin accordance with the present disclosure;

FIG. 1B is a schematic of an exemplary embodiment of a mechanical unitin accordance with the present disclosure;

FIG. 1C is a schematic of an exemplary embodiment of a mechanical unitin accordance with the present disclosure;

FIG. 1D is a schematic of an exemplary embodiment of a mechanical unitin accordance with the present disclosure;

FIG. 2 is a process flow diagram of an exemplary method of limitingtorsion in accordance with the present disclosure;

FIG. 3 is a perspective view of an exemplary embodiment of a solartracker in accordance with the present disclosure;

FIG. 4 is a detail cutaway view of an exemplary embodiment of a solartracker including a torsion limiter in accordance with the presentdisclosure;

FIG. 5 is a detail cutaway view of an exemplary embodiment of agear-driven mechanical unit including a torsion limiter in accordancewith the present disclosure;

FIG. 6 is a perspective view of an exemplary embodiment of a multiplefriction plate torsion limiter in accordance with the presentdisclosure;

FIG. 7A is a perspective view of an exemplary embodiment of anindividually motorized solar tracker incorporating an exemplary torsionlimiter in accordance with the present disclosure;

FIG. 7B is a perspective view of the solar tracker of FIG. 7A;

FIG. 8 is a perspective view of an exemplary embodiment of a linked geardrive solar tracker array including an exemplary torque-limiting clutchin accordance with the present disclosure;

FIG. 9 is a perspective view of an exemplary embodiment of a push/pulltracker system incorporating an exemplary embodiment of a rotary torsionlimiter in accordance with the present disclosure;

FIG. 10 is a perspective view of an exemplary embodiment of a push/pulllinked tracker system including an exemplary embodiment of a linear slipforce limiter in accordance with the present disclosure;

FIG. 11 is a perspective view of an exemplary embodiment of a linearslip force limiter in accordance with the present disclosure;

FIG. 12A is a rear perspective view an exemplary embodiment of ahydraulic ram driven solar tracker including an exemplary over pressurevalve in accordance with the present disclosure;

FIG. 12B is a side view of the solar tracker of FIG. 12A;

FIG. 13 is a perspective view of an exemplary embodiment of a hydrauliccylinder or ram in accordance with the present disclosure;

FIG. 14 is a cutaway view of an exemplary embodiment of an over pressurevalve in accordance with the present disclosure;

FIG. 15 is a perspective view of an exemplary embodiment of a solartracker gear assembly and exemplary torsion limiter in accordance withthe present disclosure;

FIG. 16 is a side view of an exemplary embodiment of a solar trackergear assembly and exemplary torsion limiter in accordance with thepresent disclosure;

FIG. 17 is a detail view of an exemplary embodiment of a solar trackergear assembly and exemplary torsion limiter in accordance with thepresent disclosure;

FIG. 18 is side detail view of an exemplary embodiment of a solartracker gear assembly and exemplary torsion limiter in accordance withthe present disclosure;

FIG. 19 is a perspective view of an exemplary embodiment of a solartracker including an exemplary motor brake in accordance with thepresent disclosure;

FIG. 20 is a cut-away view of an exemplary embodiment of a motor brakein accordance with the present disclosure;

FIG. 21 is a perspective cut-away view of a DC brush motor as used inexemplary embodiments of the present disclosure;

FIG. 22 is a schematic diagram of an exemplary method of shorting outthe motor armature of a brush type DC motor to create a motor brake inaccordance with the present disclosure;

FIG. 23A is a perspective view of an exemplary embodiment of a limitstop in accordance with the present disclosure;

FIG. 23B is a perspective view of an exemplary embodiment of the limitstop of FIG. 23A;

FIG. 23C is a perspective view of the limit stop of FIG. 23A;

FIG. 23D is a perspective view the limit stop of FIG. 23A at an extremeposition;

FIG. 24A is a perspective view of an exemplary embodiment of a limitstop in accordance with the present disclosure;

FIG. 24B is a side view of the limit stop of FIG. 24A; and

FIG. 24C is a cross-sectional view of the limit stop of FIG. 24A.

DETAILED DESCRIPTION

In the following paragraphs, embodiments will be described in detail byway of example with reference to the accompanying drawings, which arenot drawn to scale, and the illustrated components are not necessarilydrawn proportionately to one another. Throughout this description, theembodiments and examples shown should be considered as exemplars, ratherthan as limitations of the present disclosure. As used herein, the“present disclosure” refers to any one of the embodiments describedherein, and any equivalents. Furthermore, reference to various aspectsof the disclosure throughout this document does not mean that allclaimed embodiments or methods must include the referenced aspects.

Exemplary embodiments of torsion limiters may be advantageously used inany kind of driven system that may be exposed to external forces such ashigh wind forces and could benefit from the ability to resist theexternal force at multiple points along the structure instead of just ata single point. Solar trackers are one example of such a system, andexemplary embodiments could be used in any kind of solar tracker,including but not limited to single-axis trackers such as horizontal,tilt and roll, and azimuth, as well as dual-axis trackers. Exemplaryembodiments include any solar tracker design that includes a torsionlimiter connected between the output of the drive and the collectorarray where the torsion limiter releases at a pre-set level of torsionforce. Exemplary embodiments include solar trackers that aregear-driven, hydraulically driven, or driven by any other means.Exemplary tracker geometries incorporate a worm-gear primary gear drive,either attached to the tracker frame directly or through a secondarystage such as a spur gear rack, D-ring chain drive, or cable systemmounted to one or two column supports for the tracker. Exemplary solartracker embodiments may incorporate a balanced array such that thetorsion limiter force remains constant at any tracker rotational angle.

Exemplary embodiments of the disclosure release torsion in a trackingsystem so the system moves out of a high torque position to a secondposition and stops, or if the external force is great enough, the systemmoves to an extreme position where torsion force can be resisted atmultiple points instead of at a single point, usually the center of thesystem. Alternatively, if the system encounters an obstruction such as asand dune, snow, ice, or some other external obstruction, torque fromthe system's drive motor is released from the input drive by the torsionlimiter. Furthermore, in the linked drive system, only the row or rowsthat are affected by the obstruction do not move while the otherunobstructed linked rows will continue to track. Thus, exemplaryembodiments advantageously provide the benefit of releasing twodifferent types of torque, external torsion forces from the wind and/orinternal torsion forces generated by the drive when the tracking systemoutput is obstructed.

In windy conditions, the wind force induces a hinge moment on thetracker system. If the hinge moment is greater than the holding force ofthe torsion limiter, the torsion limiter releases the torsion and thetracker moves to second position at which the force may be lessenedbecause the wind gust has reduced or the hinge moment has been reducedas a result of the new rotational position. If the movement continuesand the system is driven to the extreme position multiple mechanicalstops, then the wind can be resisted at multiple points instead of at asingle point. Advantageously, systems employing exemplary embodiments oftorsion limiters react in a natural or passive way, without the need forelectronics such as a motor or active release. In exemplary embodiments,the torsion limiter is a clutch assembly which passively slips and hasthe opportunity to correct itself twice a day, once in the morning andonce in the evening as the motor drives the system into the extreme stoppositions.

As the wind acts on a tracked PV array, the wind normally causes a hingemoment M_(H) to occur about the rotational axis of the tracker as shownin FIGS. 1A-1D. The features and characteristics of an exemplary solartracker subject to the wind are designated as follows:

Symbol Feature or Characteristic A_(S) Module Surface Area M_(H) HingeMoment due to wind loading M_(G) Total Ground Moment Reaction R_(D)Ground Drag Reaction R_(L) Ground Lift Reaction Θ Tracker Angle fromy-axis F_(D) Drag Force due to wind loading F_(L) Lift Force due to windloading q_(z) Dynamic Velocity Pressure of wind Γ Yaw Angle of Wind fromthe y-axisAs mentioned above and described in more detail herein, exemplarytorsion limiters and related gear drives and solar trackers reduce oreliminate the hinge moment on the tracker.

FIG. 2 shows an exemplary method 1000 incorporating a torsion limiter. Atorsion limiter is any device that can limit, release, relieve, orotherwise reduce the level of torsion, torque, or other external forceon a system by any means, including but not limited to, slipping,de-coupling force, releasing pressure, facilitating movement, orseparating components of a system. As discussed in more detail herein,there are many design variants of torsion limiters. The system may beconfigured to have a pre-set limit on the level of torsion to which itcan safely be exposed (1010). When an external force causes a level oftorsion on the system to exceed the pre-set limit (1020) the torsionlimiter acts to reduce the level of torsion on the system (1030). Asdiscussed in more detail herein, depending on the type of torsionlimiter, the torsion reduction action can be slipping (1040), releasingpressure (1050), and/or facilitating rotational movement of the systemin the direction of the torsion (1060).

In exemplary embodiments, when the system moves in the direction of thetorsion it de-couples excess torsion such that the external force isreleased and the level of torsion on the system is reduced (1070). Inexemplary embodiments, the system's movement in the direction of thetorsion means the system moves from a first position to at least onesecond position (1080). The system may hit a maximum position stop inthe at least one second position (1090). If the movement is rotationalmovement, the maximum position stop may be at a maximum angle ofrotation (1100). The movement in the direction of the torsion may befrom a first position to multiple positions (1110). In exemplaryembodiments, the system is constrained in its maximum positions atmultiple distributed locations along a torsional resisting structure ofthe solar tracker assembly (1120).

Referring to FIGS. 3-5, an exemplary embodiment of a gear-drivenmechanical system 10 and a torsion limiter 18 will be described.Gear-driven mechanical system 10 may be any kind of mechanical systemhaving one or more mechanical units and using gears to drive mechanicalcomponents for rotation, movement and/or to generate work, including butnot limited to transportation systems, agricultural systems,manufacturing systems, and energy conversion and/or power generationsystems. An exemplary gear-driven mechanical system 10 comprises atleast one gear-driven mechanical unit 12 that includes a gear rack 14.The mechanical system 10 may also include a gear drive system 16 thatincorporates a torsion limiter such as a torque limiting clutch 18. Moreparticularly, an exemplary gear drive system 16 comprises a torquelimiting clutch 18 and a gear assembly 20 including at least one gearwheel 22.

A motor 15 may be provided to drive the gear drive system 16, which inturn rotates a beam or tube, e.g., torsion tube 34, directly, or drivesa gear rack 14, which in turn drives the torsion tube or other modulemounting beam structure 34. As illustrated in FIG. 3, the gear rack 14may be a spur gear rack or D-ring chain drive, which is affixed to arotatable tube, e.g., torsion tube 34, of the mechanical unit 12. Thus,when activated by gear drive system 16, a mechanical unit 12 is rotated.In exemplary embodiments, the torque-limiting clutch 18 is located at anoutput of the gear assembly 20, on the first gear stage of themechanical unit 12, and prior to a location where the gear drive system16 engages the gear rack 14 of the mechanical unit 12. A second, third,etc. mechanical unit, similar to tracking assembly 12 can be connectedto drive shaft 25 with a separate and similar worm assembly. This can berepeated for several mechanical units in a gear-driven mechanicalsystem.

Turning to FIGS. 4 and 5, an exemplary embodiment of a torque-limitingclutch 18 can be seen in a cutaway section view of an exemplary gearbox24. The gear wheel 22 may be any kind of gear wheel and is shown, by wayof example, as a worm wheel which engages worm 21. As best seen in FIG.5, the worm wheel 22 may define two taper sections 26 at the center. Inexemplary embodiments, the clutch 18 is located at these taper sections26. In exemplary embodiments, there may be two steel tapers 26 thatengage the worm wheel gear 22 under spring tension. The clutch may beadjustable via a nut 44 or other equivalent mechanism that varies thespring tension on the taper 26. Gearbox output shaft 43 connects thegearbox 24 to the gear rack 14. In exemplary embodiments, springs 19 areprovided on the output shaft 43. The springs could be in the form ofwashers 19 such as Belleville washers. As best seen in FIG. 5, thewashers 19 are conical discs facing each other on the output shaft 43outside the gearbox 24. The washers 19 act as springs that provide thepressure for the conical sections against the worm wheel 22.

When a level of torque on the gear assembly 20 exceeds a preset levelthe clutch 18 slips. More particularly, when the friction of the clutch18 on the tapers 26 is overcome due to increased torque, the clutch 18will slip. This advantageously releases the torque on the gear-drivenmechanical unit 12. This torque-release feature is particularlyadvantageous in exemplary embodiments where the mechanical units 12 arerotatable because it limits the hinge moment H_(M) about the rotationalaxis of the units.

Various mechanical conditions may occur in exemplary embodiments of aclutch, gear drive, and mechanical system with one or more mechanicalunits, which may be a solar tracking system that includes one or moretrackers. Referring to FIGS. 1 and 3, an exemplary solar tracker 12comprises at least one support column 32, which may be any shape andcomposed of any material so long as it is capable of supporting the PVmodules and other components mounted thereto. Exemplary embodiments of asolar tracker 12 include two spaced-apart support columns 32 a and 32 b.A torsion beam 34 or other tracker structure is connected to the supportcolumn 32. More particularly, the torsion beam bridges the two supportcolumns 32 a, 32 b and may be attached to the support columns by abearing 36 and bearing housing arrangement including any suitablefasteners.

The torsion beam 34 may be any shape or configuration suitable forsupporting a mounting rack or other mounting mechanism, includingmultiple connected beams, and in exemplary embodiments it has acircular-, square- or hexagonal-shaped cross section. In a system thathas overhung weight, the overhung dead load torsion varies as the systemrotates. Alternate exemplary torsion beam embodiments may be configuredwith a balanced center of gravity, such that the weight of the array isrotated about the balance point. This balanced system may beadvantageous to incorporate into the torsion limiting design because,without any overhung weight, it will keep the torsional release forceconstant at all rotational positions.

A pivot axis 40 extends through the torsion beam 34, and the torsionbeam 34 may pivot or rotate about the pivot axis 40. Solar modules 42may be mounted to the solar tracker 12, either mounted on the torsionbeam 34 using clamps 35 or via a module mounting bracket assembly. Itshould be noted that solar trackers could employ more than one torsionbeam in a double- or multiple-beam torsion structure arrangement. Insuch embodiments, a tracker would have two or more torsion beams runningalong its length. A row of multiple trackers could have two or moretorsion beams running along the length of the row.

In exemplary embodiments, the gear drive system 16 of the solar tracker12 incorporates a torque-limiting clutch 18 on the first gear stage ofthe solar tracker 12. Exemplary embodiments could include a single-stagegear-driven solar tracker where the gear drive system 16 is asingle-stage worm gear drive that directly rotates the solar collectorarray. The torsion limiter, in the form of a clutch, could be locatedbetween the connection of the output of the worm gear drive and thesolar collector array. Exemplary embodiments also include two- ormulti-stage solar trackers. Gear assembly 20 includes at least one gearwheel 22, and in exemplary embodiments the gear wheel is a worm wheel.

In exemplary embodiments, the torque limiting clutch 18 is locatedbetween the connection of the output of the first stage worm gear andthe second stage gear. The second or multiple stage gear or gears may beconstructed of any type of bi-directional gear drive system capable oftransmitting rotary force bi-directionally, including but not limitedto, a spur gear, pin gear, cable drive, belt or chain drive. Thetorque-limiting clutch 18 may be located at an output of the gearassembly 20, on the output of the first gear stage of the solar tracker12, and prior to a location where the gear drive system 16 engages thegear rack 14 of the solar tracker 12. As discussed above, the clutch 18may be located at two taper sections 26 of the worm wheel gear 22. Thetwo steel tapers 26 engage the worm wheel gear 22 under spring tension,which may be adjustable via a nut 44 or other adjustment mechanism.

In exemplary embodiments, the torque-limiting clutch may be incorporatedinto a plurality of solar trackers 12 connected into an array layoutcomprised of one or more rows 46 of solar trackers. More particularly,multiple solar trackers 12 may be mechanically linked in a large arrayconfiguration 50 so they may operate in unison, driven by a single motorand tracker controller. The array configurations could be implemented byproviding a rotary drive linkage system underneath the solar trackerarray. Another bearing system, such as a slew drive, may also beincorporated in the fixed-tilt azimuth tracking geometry if it isproperly designed to withstand the load forces applied near the base ofthe array support. In alternative exemplary embodiments, the array couldhave a motor at each solar collector gear drive. In single motorizedgear drive embodiments, a torsion limiting feature may be incorporatedinto the motorized gear drive assembly. In exemplary embodiments, thedrive system could incorporate the linked worm-gear drive into acarousel type fixed tilt azimuth tracking array field. In suchembodiments, the tilted solar array is rotated on a large area circularbearing to track the sun.

Turning to FIG. 6, an exemplary embodiment of a high-torsion, springforce, multiple-plate torsion limiter 718 may be comprised of multipleinterleaved spring loaded friction plates 715. Springs 717 create afriction force on the friction plates 715 causing an increase in thefriction surface area of the torsion limiter 718. This design is anexemplary variant of the spring loaded tapered cone torsion limiterdepicted in FIGS. 4 and 5. The inside diameter may be connected to oneshaft and the outside diameter connected to a different shaft. Thetorsion limiter 718 limits the torsion between the two shafts. Thetorsion limiter can be incorporated inside a worm gear drive unitbetween the gearing and the output, as shown in FIG. 7B, or mountedoutside of the worm gear unit on the connection of the torsion tube tothe worm gear unit, as illustrated in FIG. 7A. Alternatively, it can beconnected to the torsion tube on the inner diameter and the linear armto limit torsion on the array of a linked tracking system, as in FIG.10.

Exemplary embodiments of systems using torque-limiting clutch assembliesare shown, as solar tracker systems by way of example, in FIGS. 7A-12B.In these and other embodiments, the torsion limiting clutch may be at alocation other than on the first gear stage of the tracker. Withreference to FIGS. 7A, 7B and 8, an exemplary embodiment of anindividually motorized gear-driven solar tracker 112 may have a clutch118 at the output of a gear assembly or incorporated inside the driveunit 116. Such embodiments are configured are configured similarly tothe exemplary systems shown in FIGS. 3-4, in which multiple trackers aredriven by a single motor, and the torque-limiting clutch 18 operates inthe same way, providing the same advantages. In an exemplary solartracker assembly 112, torsion beam 34 is connected to the support column32, and solar modules 42 may be mounted to the tracker 112.

In an exemplary embodiment, illustrated in FIGS. 7A and 7B, the torsionlimiter or clutch 118 may be located on the connection of the output ofthe gear drive unit 116 to the torsion tube 34 of an independentlymotorized gear-driven solar tracker 112. More particularly, the clutch118 is mechanically connected to the output of the gear assembly (withindrive unit 116). Alternatively, the clutch may be incorporated intoother stages of the gear train such as between a brake motor and abi-directional gear drive. Additional torsion limiting clutches 118 maybe provided and, in exemplary embodiments, are located between a rotaryactuator 111 and the torsion beam 34 of the tracker 112. In exemplaryembodiments, the drive unit 116 houses a torque-limiting clutch. FIG. 8shows an exemplary embodiment of a linked single-stage gear drivetracker 112 arranged in multiple rows 46 in which two torsion limitingclutches 118 are incorporated on the output of the main driving gear116.

FIG. 9 shows an exemplary embodiment of a push/pull tracker 212 with atorsion limiter 218 on the connection of the torque arm to the torquetube 34. In exemplary embodiments, a rotary clutch could be located inthe main torsion element or on the output of the gear of any kind oftracker. As shown in FIG. 9, in exemplary embodiments a torsion limiter218 could be incorporated between the arm connection of the output ofthe gear drive unit 216 and the torsion tube 34 of a push/pull trackersystem. More particularly, the rotary clutch 218 is mechanicallyconnected to the gear rack 214 of the solar tracker 212, while the gearrack 214 is operatively connected to the torsion beam 34. In exemplaryembodiments, the torsion limiter could be a rotary torsion limiter.

Referring to FIGS. 10-11, an exemplary embodiment of a push/pull linkedsolar tracker system 310 is shown. Here, the linkage could incorporate alinear slip force limiter 318 at each tracker 312 to achieve individualrow movement to an extreme position during high winds. An exemplaryembodiment of a linear force limiter 318 is shown in FIG. 11. Inexemplary embodiments, the linear clutch is a friction linear slide 318that allows the tracker to rotate while the linear linkage slips in alinear motion. Friction linear slide 318 is composed of a tube 319 and aclamp 321 which slides on the tube. The clamp 321 is mounted to the tubevia trunion mount 323 and a friction mate 325 is located between theclamp 321 and tube 319. This linear friction slide device 318 can beplaced in the push/pull linkage of a solar tracker. When the torsionalforce externally applied to the tracker is greater than the forcerequired to overcome the friction of the slide 318, then the torsionalforce would be released and the tracker would be allowed to move. Itshould be noted that a push/pull tracker system may be individuallydriven or linked together with a linear drive motion.

With reference to FIGS. 12A, 12B, 13 and 14, exemplary embodiments ofhydraulically driven tracker systems 412 could employ a torsional relieffunction in the form of an over-pressure relief valve 418 to allow thetracker 412 to move to an extreme position in conditions where thetracker is exposed to excess wind force. A double acting hydraulic ram460, or cylinder, as shown in FIG. 13, could be used to drive thehydraulic tracker 412. Exemplary embodiments of a hydraulic ram 460 hasa rod 461, which could be a rod, seal 465 and other sealing components463, an extend port 462 and a retract port 464. The linear motion ofhydraulic ram 460 may be converted into rotary motion and used in apush/pull tracker design, discussed above with reference to FIGS. 10-11.

In exemplary embodiments, hydraulic ram 460 may be fitted with anover-pressure valve 418 such as the one shown in FIG. 14. An exemplaryover-pressure valve 418 has a spring 472 contained within the valvebonnet 476. A seat disc 478 is held by a disc holder 480 within body474. The valve 418 may further comprise a blowdown adjustment ring 482and a nozzle 484. The over-pressure valve 418 may be incorporated intothe hydraulic fluid circuit between the two chambers of the hydraulicram 460 that positions and holds the rotational position, i.e., it maybe located between the extend port 462 and the retract port 464 of thehydraulic ram 460.

This allows movement in the ram 460 when the torsion externally appliedto the tracker system creates an over-pressure in the hydraulic ram.More particularly, when enough pressure hits the over-pressure valve418, it hydraulically releases, acting as a torsion limiter for thetracker. The over-pressure relief valve 418 is designed or set to openat a pre-set pressure to release excess torsion externally applied tothe tracking system 412. The pressure is relieved by allowing thepressurized fluid to flow between the two chambers of the hydraulic ram,pressure controlled by the valve 418. An air actuated tracker systemcould also employ a wind induced torsion relief in the form of anover-pressure relief valve to achieve the same function.

Exemplary embodiments of a motorized gear rack/tracker row assembly willnow be described with reference to FIGS. 15-18. A gear rack 814 iscoupled to the torsion tube 834 of a solar tracker assembly 812 and mayalso be attached to a support column 832 of the tracker assembly. Moreparticularly, the gear rack 814 may be affixed to the torsion tube 834via torsion tube bearing assemblies 836 and coupler 823. In exemplaryembodiments, the gear box 824 has an internal clutch (not shown) locatedat an output of the gear assembly 820, which includes the gear rack 814,a pinion gear 815 with pinion gear shaft 817, and may include a gearshaft end bearing. The system may have a gear drive upright columnassembly with a driving motor 821 and driving the gearbox 824. One ormore photovoltaic modules 842 may be coupled to the torsion tube 834using module mounting brackets 835.

FIG. 17 shows a detail view of the end travel position of the gear rack814 and the engagement of the pinion gear 815. In exemplary embodiments,the pins 825 of the gear rack 814 are advantageously positioned at ornear the end of the gear rack 814 to effect a stop as the pinion gear815 rolls into the changed positioning of the pins 825. As best seen inFIG. 18, the pinion 815 may have center ridged pins 825 and a slottedpinion gear. This arrangement advantageously assures that the piniongear 815 contacts only the pins 825 of the gear rack 814 and not theside plates of the gear rack.

Turning to FIGS. 19-22, in exemplary embodiments a single motorizedsolar tracker 512 incorporates a torsion limiter device which could be amotor brake 518. As best seen in FIG. 20, an exemplary motor brake wouldaffix to an electrical motor. The motor brake 518 may include anysuitable combination of pressure plate and disc components. In exemplaryembodiments, the internal components include a stationary disc 521 aswell as one or more rotating friction discs 523 having a hub and shaft.The brake is electrically released during motor operation and engagedwhen the motor is de-energized. A pressure plate 525 pushes against thediscs, and a self-adjusting mechanism 527 may be provided to adjust thepressure on the discs. A release lever 529 allows for manual release ofthe pressure.

In exemplary embodiments, an individual motor could be located at eacharray. In exemplary embodiments, a gearing system that is capable ofbeing bi-directionally driven could be coupled to a motor and a motorbrake 518 at each array. The motor could have a brake in the motorsystem or use itself as a brake. With the proper sizing of the motor,the brake, and the gear ratio and gear efficiency, the motor or motorbrake 518 may act as the wind force release in the system. In exemplaryembodiments, the drive system comprises a bi-directional gearbox 514,and the motor brake 518 is located at the input of the gearbox 514. Thebi-directional gearing can be driven from the gearbox input or outputand has the capability to be driven from either the output or the input.In exemplary embodiments, the bi-directional gearing could be anysuitable gear, including but not limited to a spur gear, helical gear,planetary gear, high efficiency low ratio worm gear, belt drive, chaindrive or other bi-directional drive arrangements.

In exemplary motor brake embodiments the torque in the torsion tube 34,as applied by external forces such as wind, is reduced by the gear ratioof the bi-directional gearing, which overcomes the motor brake force.Then the torsion is released at the output and the tracker arrayrotates. In this embodiment, the motor brake 518 is configured to lockthe solar tracker 512 in position until a pre-set torque limit isreached, at which time the motor brake slips. Exemplary embodimentscould incorporate a mechanical brake within the motor or affixed betweenthe motor and the gear drive. If the motor itself has a separate brakeas in FIG. 21, then the motor may be sized for moving the arrayseparately from the torsion release force required to hold the array.

As shown in FIG. 21, the motor brake could be a brush-type directcurrent motor 618 that has the input power leads, such as lead wire 635,shorted to effect a brake action on the motor output. If designed with abrush-type DC motor and sized properly with the gear ratio and the sliptorque, the motor itself may be used as a the slip clutch for theexternal torsion to overcome. A DC brush-type motor 618 with its powerleads shorted together act as a brake by turning the motor into agenerator with a shorted output, making the motor difficult to turn. Inexemplary embodiments, brush-type motor 618 has an internal commutator631 to periodically reverse the direction of the current and at leastone brush 633 in contact with the commutator to complete the switch.

An exemplary circuit diagram showing incorporation of a motor isillustrated in FIG. 22. FIG. 22 shows an exemplary method of shortingout a motor, in this exemplary embodiment brush motor 618, so it acts asa shorted out generator. The H-Bridge turns on the motor and the motormay be shorted out via relay 619. When this happens, the brush motor 618acts like a fully-loaded generator so it is hard to turn and acts as abrake on the solar tracking system. The motor 618 may incorporate abrake 637, which could be a negative actuated-type electromagneticbrake. It should be noted that a motor brake could be incorporated inany one of a variety of solar tracker assemblies, including but notlimited to an individually motorized single, multi-stage orbi-directional gear driven system. When an external force causes a levelof torsion on the drive system to exceed the pre-set limit the motorbrake is overcome and facilitates back-driving of the drive system.

Turning to FIGS. 23A-23D, an exemplary embodiment of a bearing stopassembly 70 will be described. An exemplary bearing stop assembly 70comprises a bearing housing 72, a dry slide bearing 74 and an internalrotating stop block 76. FIG. 23B depicts the stop block 76 engaged atone side of its limit of rotation, i.e., one extreme stop position. FIG.23C shows the stop block 76 in middle position, i.e., in the middle ofthe allowed rotational motion. FIG. 23D shows the stop block 76 at theopposite extreme stop position of FIG. 23B. The bearing stop assembliesmay be placed at every column and may be attached to the torsion tube34. Bearing stop assemblies 70 advantageously provide the triplefunction of supporting the solar tracker array, providing a bearing onwhich the array can rotate, and, as discussed in detail herein,functioning as mechanical stops at the trackers' maximum rotationalpositions. The housing may be coated with a low friction coating toprevent stick or slip action in the slow moving bearings.

FIGS. 24A-24C illustrate another exemplary embodiment of a trackerbearing stop assembly 170 with integral grounding. An exemplary assembly170 comprises a bearing housing 172, a pin and roller bearing wheels173, a dry slide top half bushing 174 and an internal rotating stopblock 176. Advantageously, this design may provide better performance industy environments and also provides a continuously electricallyconductive grounding path, eliminating the need for an external groundwire to electrically bond the torsion tube to the column.

With reference again to FIG. 23A, an exemplary embodiment of a bearingstop assembly 70 can be seen fully mounted in a solar trackerapplication where the solar tracker 12 has photovoltaic modules 42mounted to the torsion tube 34 with special module mounting brackets. Anadditional bracket may be provided which allows a damper to be connectedbetween the torsion tube 34 and the support column 32 of the tracker. Adamper may be incorporated at the gear drive to control the rate atwhich the tracker rotates during an over torque event. When the torsionis relieved by allowing the system to rotate, the speed at which thearray is allowed to move may be controlled by the slip friction of theclutch, or by an external damper or both.

In exemplary embodiments, the bearing stop assembly 70 is connected to aU-bracket 78 that connects to an I-beam column 80. As shown, the bearingstop assembly 70 is mounted to an exemplary octagonal torsion tube 34,such that the torsion tube runs through the center of the bearing stopassembly. It should be noted that the torsion tube could be anycross-sectional shape including but not limited to circular, rounded,ovular, square, rectangular, triangular, pentagonal, hexagonal, andoctagonal. The stop block 76 in the bearing stop assembly 70 may beconfigured as a ring which conforms to the outside shape of the torsiontube 34 so that it is keyed to the outside of the tube and rotates withthe tube.

In exemplary embodiments, the dry-slide bearing 74 also conforms to theoutside shape of the torsion tube 34 and rotates with the tube. As shownin FIG. 23A, the dry slide bearing 74 may be octagonal on the internaland round on the external. The round external shape of the dry-slidebearing 74 slides on the round internal shape of the bearing housing 72.This interface of the external surface of the dry-slide bearing 74 andthe internal surface of the bearing housing 72 forms the bearingsurface. In exemplary embodiments, the bearing surface of the bearinghousing 72 may be coated with a low friction coating to reduce frictionin the bearing. The dry-slide bearing 74, is typically formed frompolymer material and may also incorporate friction-lowering agents inits composition to reduce friction. When the torsion tube 34 is rotatedto the mechanical limits, the stop block 76 engages the bearing housingto eliminate further rotation of the torsion tube 34. There aretherefore two extreme rotational stop positions created by the stopblock 76.

In operation, the wind induces a hinge moment M_(H) on the gear-drivenmechanical system 10. With reference to FIGS. 1-5 and other illustrativeembodiments, the clutch may be pre-set to slip at a fraction of themaximum induced hinge moment torque. When the hinge moment H_(M) inducedby the wind reaches the preset torque limiting value, the friction ofthe clutch 18 on the tapers 26 is overcome and the clutch 18 slips. Ineffect, the clutch 18 acts like a pressure relief valve for the hingemoment M_(H) induced by the wind, advantageously releasing the torque onthe gear-driven mechanical unit 12. With the level of torque sufficientto slip the clutch, a row of gear-driven mechanical units 12 may rotateout of position and into a lower hinge moment position.

When the torsion exerted externally on the output of the gear drivesystem (the collector array) exceeds a pre-set limit, the torsionlimiting device allows the array to move into a new position until theforce has diminished below the torsion threshold or the array hasreached its mechanical limits. In the case where the torsion exertedfrom the input exceeds the pre-set torsion limit on the array, thetorsion limiting device de-couples the excess input force and allows theinput to move without affected movement on the array. As discussed inmore detail herein, this may be used to synchronize linked arrays whendriven against a mechanical stop, or used when natural occurrences suchas snow drifts or sand impede array movement. In this case, it isadvantageous to de-couple the input driving forces with the torsionlimiter and hold the array output at position.

In exemplary embodiments, when wind speed forces exceed the torquerequired to slip the clutch in the drivetrain, then the solar array orother gear-driven mechanical unit 12 rotates to another position. Ifthis excess torque continues from the wind, then each mechanical unit 12and the array 50 of units moves to its maximum angle of rotation 54, anextreme rotational angle where the torsion force can be resisted atmultiple locations on the torsion tube 34. The row of mechanical units12 may be rotated by the wind until the maximum angle stop is reached.

In exemplary embodiments, the system may hit mechanical stops 58 on eachrow of mechanical units 12 each time the row moves to an extremeposition during normal operation. Allowing the external force to rotatethe row of solar trackers while driving the other rows of solar trackersallows each row to reach its maximum limit position until all of rows ofsolar trackers are aligned. Advantageously, this ensures alignment ofall rows of units 12 twice a day in the event that the wind moves a row.This ensures that all the rows are exactly synchronized at least onceper day. At the commissioning of a new project, the tracker rows may bepointing all directions, but after a calibration, the rows would becompletely synchronized. It should be noted that in a linked solartracker system the clutch 18 may act independently at each tracker row.This is because having a back-drivable linked system that has to backdrive all tracker rows may not react properly to protect each row whenthe wind force is applied individually to a row.

In exemplary embodiments, the rotation speed may be regulated by theclutch slip force. Advantageously, the clutch 18 may de-couple thedynamic loads on the system by eliminating the spring in the system,thereby significantly reducing the design loads. Alternatively, dampers58 may be provided to slow the motion of the tracker. The max angle stopmay then be resisted not only by the gear rack, but by the dampers atthe gear rack or stops 58 at the end of the rows of mechanical units 12,thereby sharing the torsion load of the gear rack 60 and distributingthe torsion load through multiple points on the torsion tube 34. Thedampers 58 may serve double duty as stops at the end of the array, ordampers placed at any location may be designed to assist in regulatingthe torsional release reaction speed and resisting the hinge momentloads.

Advantageously, exemplary embodiments reduce the maximum hinge moment,eliminate the dynamic loading, and allow gear-driven mechanical systemsto resist the hinge moment forces at multiple points on the arrayinstead of at a single point. It is typical that the hinge moment forcesare greater at small tilt angles and reduce as the array tilt anglesincrease. In exemplary embodiments, at the extreme vertical stoppositions, the maximum hinge moment force will be less than at the smallangles of rotation and will only occur at the mechanical stops at therange of motion extremes. The total hinge moment may be resisted in morethan just the central gear. Range of motion mechanical stops may beplaced at any location on the array, typically at the distributedvertical supports, to assist in resisting the hinge moment loading,thereby minimizing torsion loads at any single point in the system.

Referring again to FIGS. 1 and 3, the maximum hinge moment may be x ftlbs, and the clutch 18 slips at about x/4 ft lbs. Accordingly, thetorsion tube 34 need only resist a maximum of x/4 ft lbs at the geardrive 16 prior to the clutch 18 slipping. In this exemplary embodiment,at the maximum angle of rotation 54 the maximum hinge moment is about xft lbs, the gear resists x/2 ft lbs and the stops located at the ends ofthe tracker must resist x/4 ft lbs so the maximum torsion load in thetube 34 is x/4 ft lbs. The maximum torsion values would likely be doublein each component without advantageous use of exemplary embodiments ofthe clutch and multiple stops. These values can be reduced further byallowing the torsion release to occur at lower values and using morestops than only at the ends of the array, such as at every column.

In exemplary embodiments, the driveline and the gear rack would not seeone gear rack 14 stopping the force from the motor 15. Accordingly, thegear rack and the driveline can be more minimally constructed. Moreover,exemplary systems would need only be constructed to see the motionrestricted to the everyday range of motion and over travel protectioncould be incorporated into the torsion limiter. The dampers 58 and gearrack 14 may be optimally designed and implemented at full range ofmotion. No extra tolerance on range of motion is necessary other thanthe daily range of motion.

Advantageously, in exemplary embodiments if one row of mechanical units12 has a mechanical bind, it will not affect the rest of the system 10.This may be helpful as it may self-diagnose a tracker row bindingproblem. If the outer rows move to an extreme angle from the wind, theymay act as wind blockers to the inner rows. Because the forces of lift,drag and hinge moment occur in combination on the system and each ofthese loads may peak at different specific rotational angle positions,it may be advantageous to allow a row of mechanical units to move into amore extreme angle position prior to the maximum lift force conditionoccurring. If this is reliably accomplished via the torsion limitersdiscussed herein, then the foundation design value for maximum lift willbe lower and therefore the size and/or depth required for the systemfoundation may be lessened to resist the lower lift force.

The torsional strength requirements may be less because the maximumtorsion can be resisted at multiple points and not at the maximumrotational angle for peak hinge moment. The drag force peak may notchange since the system typically is designed for the extreme rotationalangle position in the case of horizontal solar trackers, but may belessened in other solar tracker geometries. The maximum combined forcemay also be less, in which case the overall structural requirements willbe lessened. These force reductions equate to reductions in thestructural requirements of the mechanical systems. A reduction instructural material typically equates to a substantial material costsavings and may also equate to labor savings, therefore the overallinstalled cost of the system may be reduced.

Thus, it is seen that torsion limiter devices, systems, and methodsincorporated into systems such as solar trackers are provided. While thesystems, devices, and methods have been described in terms of exemplaryembodiments, it is to be understood that the disclosure need not belimited to the disclosed embodiments. Although illustrative embodimentsare described hereinabove, it will be evident to one skilled in the artthat various changes and modifications may be made therein withoutdeparting from the disclosure.

It should be understood that any of the foregoing configurations andspecialized components or chemical compounds may be interchangeably usedwith any of the systems of the preceding embodiments. It is intended tocover various modifications and similar arrangements included within thespirit and scope of the claims, the scope of which should be accordedthe broadest interpretation so as to encompass all such modificationsand similar structures. The present disclosure includes any and allembodiments of the following claims. It is intended in the appendedclaims to cover all such changes and modifications that fall within thetrue spirit and scope of the disclosure.

What is claimed is:
 1. A solar tracker assembly comprising: a supportcolumn; one or more torque tubes or torsion beams connected to thesupport column; a mounting mechanism attached to the one or more torquetubes or torsion beams; a drive system connected to the one or moretorque tubes or torsion beams; and a torque limiter connected to anoutput of the drive system of a tracker row; wherein when a hinge momentforce causes a level of torque on the drive system to exceed a pre-setlimit the torque limiter passively allows rotational movement of thetracker row in the direction of the torque, thereby allowing the hingemoment force to rotate the tracker row about a pivot axis such thathinge moment is reduced or eliminated as a result of a new rotationalposition of the tracker row independently of a plurality of trackerrows.
 2. The solar tracker assembly of claim 1 wherein the movement inthe direction of the torque de-couples excess torque such that the hingemoment force is released and the level of torsion on the solar trackerassembly is reduced.
 3. The solar tracker assembly of claim 2 whereinthe movement in the direction of the torque comprises movement of thesolar tracker assembly from a first rotational position to at least onesecond rotational position.
 4. The solar tracker assembly of claim 3further comprising one or more mechanical stops connected to the supportcolumn, the mechanical stops being located at the solar tracker'smaximum rotational position; wherein the solar tracker assembly hits amaximum position stop in the at least one second rotational position. 5.The solar tracker assembly of claim 3 wherein the solar tracker assemblyis constrained in its maximum rotational positions at multipledistributed locations along the solar tracker assembly.
 6. The solartracker assembly of claim 1 wherein the solar tracker assembly includesa plurality of support columns supporting a tracker row and furthercomprises a stop at each support column.
 7. The solar tracker assemblyof claim 6 wherein the stops distribute the torque force resistancewithin the tracker row when the tracker row reaches its maximumrotational position.
 8. The solar tracker assembly of claim 1 whereinthe drive system comprises a gear assembly including at least one gear.9. The solar tracker assembly of claim 8 wherein the gear assemblyincludes a one-way gearbox and the torque limiter is a torque limitingclutch contained within the gearbox.
 10. The solar tracker assembly ofclaim 8 wherein the gear assembly includes a friction coupling engagingthe gear wheel and the torque limiter is located at the frictioncoupling.
 11. The solar tracker assembly of claim 8 wherein the torquelimiter is located at the output of a first gear stage of the gearassembly.
 12. The solar tracker assembly of claim 1 wherein the solartracker assembly is a push/pull linked tracker and the torque limiter isa linear slip device.
 13. The solar tracker assembly of claim 1 whereinthe solar tracker assembly includes a hydraulic system and the torquelimiter is a pressure relief valve.
 14. The solar tracker assembly ofclaim 1 further comprising a damper to control release of torque forceand slow motion of the solar tracker assembly.
 15. The solar trackerassembly of claim 1 wherein the one or more torque tubes or torsionbeams are configured with a balanced center of gravity such that one ormore of the torque tubes or torsion beams rotate about the balancedcenter of gravity.
 16. A method of aligning a solar array, comprising:providing a plurality of rows of solar trackers including multiple rowsof linked solar trackers; providing a torque limiter connected to eachtracker row; receiving a hinge moment force on at least one tracker rowsuch that a level of torque on the at least one tracker row exceeds apre-set torque limit; passively allowing rotational movement of the atleast one tracker row; causing the at least one tracker row to stoprotational movement independent of the multiple rows of solar trackerswhen the at least one tracker row moves from a first rotational positionto a second rotational position; and the motor driving other trackerrows while slipping the torque limiter on each tracker row at themaximum rotational limit of each tracker row such that each tracker rowreaches its maximum rotational limit until all of the plurality of rowsof solar trackers are aligned.
 17. The method of claim 16 wherein eachtracker row includes a plurality of support columns and furthercomprising providing a stop at each support column.
 18. The method ofclaim 17 wherein when each tracker row reaches its maximum rotationallimit position the torque is distributed between each stop at eachsupport column.
 19. A solar tracker assembly comprising: a supportcolumn; one or more torque tubes or torsion beams connected to thesupport column; a mounting mechanism attached to the one or more torquetubes or torsion beams; a drive system connected to the one or moretorque tubes or torsion beams; and a torque limiter connected to thedrive system; and one or more stops connected to the support column, thestops being located at the solar tracker's maximum rotational position;wherein when a hinge moment force causes a level of torque on the drivesystem to exceed a pre-set limit the torque limiter allows rotationalmovement of the solar tracker assembly, thereby allowing the hingemoment force to rotate the solar tracker assembly into a lower hingemoment position; and wherein the solar tracker assembly hits a maximumposition stop and is constrained in its maximum rotational positions atmultiple distributed locations by the stops.
 20. The solar trackerassembly of claim 19 wherein the torque limiter is a motor brake. 21.The solar tracker assembly of claim 20 wherein the motor brake isaffixed to a motor and connected to a bi-directional gearing system. 22.The solar tracker assembly of claim 21 wherein when a hinge moment forcecauses a level of torque on the drive system to exceed a pre-set limit,the motor brake slips.
 23. The solar tracker assembly of claim 21wherein the motor brake is internal to the motor; and wherein when ahinge moment force causes a level of torque on the drive system toexceed a pre-set limit the motor brake is overcome and the motor isdriven backwards, facilitating back-driving of the drive system.
 24. Thesolar tracker assembly of claim 21 wherein the motor is an electricmotor comprising power leads and the motor brake electrically brakes themotor by shorting the power leads.
 25. The solar tracker assembly ofclaim 21 wherein the bi-directional gearing system comprises at leastone gear element of a back-driveable worm gear.
 26. The solar trackerassembly of claim 19 wherein the hinge moment force is caused by anexternal obstruction.
 27. The solar tracker assembly of claim 26 whereinthe solar tracker assembly is incorporated into multiple tracker rowshaving a linked drive system; and wherein tracker rows affected by theexternal obstruction stop moving and tracker rows not affected by theexternal obstruction continue to track.